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This white paper describes the use of Altera® FPGAs to deliver a multistandard
Industrial Ethernet capability from a single PCB implementation. The benefits of
FPGA implementation are described and an overview of the FPGA development flow,
tools, and technology used to create a universal but easy-to-maintain solution is
given.
Introduction
Since its conception by Xerox in the mid-1970s and standardization as IEEE 802.3 in
1983, Ethernet has become the de facto standard for computer communication in the
business world. Ethernet networks have evolved from coaxial cable-based systems
delivering 3-Mbps performance to systems built from unshielded twisted pair
(Cat5 UTP) cables that deliver high reliability, low cost, and 100-Mbps performance.
With devices capable of 1-Gbps Ethernet already in the market and 10-Gbps on the
horizon, the continuous evolution of Ethernet (see Table 1) will continue to service
market requirements long into the future.
Table 1. Evolution of the Ethernet Standard
Year Standard Summary
1983 IEEE 802.3 Basic Ethernet standard
1985 IEEE 802.3a 10Base2 thin Ethernet standard
1990 IEEE 802.3i 10Base-T 10-Mbps Ethernet standard
1995 IEEE 802.3u 100Base-TX/T4/FX 100 Mbps (fast Ethernet)
1997 IEEE 802.3x Full-duplex Ethernet standard
1998 IEEE 802.3y 100Base-T2 Fast Ethernet standard over UTP
1999 IEEE 802.3ab 1000Base-T 1 Gbps
2003 IEEE 802.3af Power over Ethernet
2006 IEEE 802.3an 10GBase-T 10 Gbps
Factories want higher bandwidth (performance) and more easily managed networks
using existing Ethernet equipment where possible to reduce the total cost of
ownership. The range, availability, and ease of implementation of Ethernet, combined
with the pressure to integrate the factory system with the corporate network, have
driven industrial developers to create Industrial Ethernet-based networking solutions
that are compatible with, or—in new or upgraded equipment—even replace,
industrial fieldbus communication solutions.
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Page 2 Implementing a Universal Industrial Ethernet Solution
Many Ethernet-based industrial communication protocols exist today, each with its
own individual pros and cons. Some of these protocols, including the popular
PROFINET, EtherNet/IP, and EtherCAT protocols, have been standardized as “open”
protocol standards so any developer can create an implementation of that protocol.
These open protocols tend to be more popular and used more widely across the
industry.
Some solutions simply bundle fieldbus or application data into standard Ethernet
packets and require nothing more than a standard Ethernet TCP/IP implementation.
This implementation lacks the real-time performance and determinism that is
required of many industrial networks today. All industrial Ethernet protocols require
additional custom software, and most of the higher performance protocols require
custom hardware as well. This combination of protocol-specific hardware and
software makes it difficult for developers to maintain a solution that supports
multiple protocols.
Not only are there many Ethernet protocols in existence, but these protocol standards
continue to evolve, leveraging changes in the base Ethernet standard and
improvements in technology. In order to compete, industrial equipment
manufacturers must find a cost-effective way to support as many Industrial Ethernet
protocols as possible and be able to quickly adopt protocol changes, support new
protocols, and incorporate other system improvements.
Cyclone®
Cyclone III
IVSeries
SeriesFPGA
FPGA
Nios®IIII
Nios MAC
MAC PHY
PHY
Optional
Optional Processor
Processor
CPU
CPU ++
Ethernet
Ethernet
Stack
Stack MAC
MAC PHY
PHY
When combined with an Ethernet transceiver (known as a PHY), the FPGA can
perform all of the functions required by the Ethernet interface. The PHY and board
electronics deal with the physical (Layer 1) interface, and the (Layer 2) media access
controller (MAC) hardware functions are configured as programmable logic to run in
the FPGA. Higher level functions (Layer 3 and up) are implemented in software
running on a processor core (such as the Nios® II embedded processor) configured
into the FPGA logic. Implementing a communication channel between an existing
application processor and the FPGA is also feasible because of the programmable
nature of the FPGA logic, the multistandard support of the I/O pins, and the
availability of a wide range of off-the-shelf interface IP. Usually, an existing interface
in the processor device (e.g., I2C, SPI, or some local parallel I/O bus) or on the system
(e.g., PCI®, PCI Express® (PCIe®), CANopen, etc.) can be used to communicate with
the FPGA. This approach offers the advantage of requiring minimal computing time
and changes to the application software running on the existing processor. This
FPGA-based approach preserves the status of the system software and brings
additional processing resources to deliver a high-performance implementation of the
Industrial Ethernet stack processing.
Because the FPGA hardware is reconfigurable, designers can create a system that
contains two or more soft microprocessor cores, enabling integration of the
application processing into the FPGA. Benefits of this type of system integration can
include reductions in component count, cost, and power consumption. In addition, an
FPGA IP-based design is protected against obsolescence due to the long device
lifetime of the FPGA and the ability to migrate easily to newer generations of FPGAs.
Devices such as Altera’s Cyclone® IV family also provide the opportunity to
accelerate system performance by implementing computationally intense functions as
Configure and
Integrate
Hardware System
Configuration Information
Software
FPGA
For each selected IP module, a configuration wizard appears that allows the selection
of appropriate options (Figure 3, right). Once this selection is complete, the configured
IP component will appear in the current system design in the pane on the right. The
component base address or interrupt levels can then be changed, and the interconnect
architecture of the system can be modified using the GUI to change the connections
between the IP components. This process (illustrated in Figure 4) allows the quick
design of modular and highly optimized systems. Design errors are flagged in the
bottom window so the designer can easily identify and fix problems like address
conflicts or incorrect component connections.
Figure 4. Using Hardware IP with SOPC Builder to Create an Industrial Ethernet-Capable System
Once the system design is complete, the designer clicks on the Generate button and
the SOPC Builder tool generates all of the HDL required to build a working system.
As the IP is pre-built and tested by the vendor, and as the system interconnect is
machine-generated, the design is correct by construction and requires minimal effort
to implement. Once the system is generated, it appears as a design block in the
Quartus II schematic editor. Then hardware synthesis, a single-button operation for
most SOPC Builder-generated systems, creates a configuration file that can be
downloaded into the FPGA.
If, later on, a new or modified design is needed, the designer just opens the SOPC
Builder tool, modifies the design through the GUI, regenerates the system, and
resynthesizes it with the Quartus II software to create another configuration file. This
means a hardware design for a new Industrial Ethernet protocol can be created by
purchasing the hardware IP required and dropping it into the existing system design
and regenerating. One click to resynthesize, and within a short time the new
hardware configuration file is ready.
Note:
(1) Please verify availability with vendors as products are subject to change.
f For further information on these Industrial Ethernet Protocol FPGA IP vendors, see
Altera’s Industrial Networking Partner Program (INPP). Each of these vendors has
proven expertise in the field, robust IP solutions, and product evaluation packages
that all work on the Industrial Networking Kit (INK) from Terasic. This means that
with one board, a designer can easily evaluate different vendors and start
development on the same board, even when using IP products from multiple
vendors.
Although IEEE 1588 is not an Ethernet protocol standard, this packet time-stamping
IP is often associated with Industrial Ethernet to improve determinism. Thus, the
vendors for this IP have been included in Table 3. FPGAs are very flexible and can
support many interface protocols and standards. For example, IP for industrial
fieldbus standards such as SERCOS II, PROFIBUS, Interbus-S, CAN, and others can
be found ready for implementation in FPGAs. Thanks to the flexibility and increasing
cost effectiveness of FPGAs, the number of supported industrial communications
standards continues to grow.
Getting Started
To evaluate the Industrial Ethernet solution that best suits a system’s requirements,
the first thing a designer will need is a development kit such as the new Cyclone IV E
Industrial Networking Kit (INK) shown in Figure 5.
Figure 5. The Cyclone IV E INK
The INK has features such as dual 10/100/1000-Mbps Ethernet ports, 128-MB
SDRAM, 8-MB flash memory, 2-MB SRAM and security EEPROM that make it ideal
for developing Industrial Ethernet solutions. It also carries HSMC and GPIO
expansion connectors that allow the board to support additional interfaces and
applications. Included in the kits is a HSMC expansion board that supports dual
CAN, dual RS-485, RS-232, and dual PROFIBUS interfaces to support a wide range of
fieldbus communication standards. Other applications that the board can support
include motor/motion control, video surveillance, and machine vision.
The INK is used by all of Altera’s INPP members as an evaluation and development
platform. The designer can use the INK to evaluate IP for multiple standards and
multiple vendors on the same board, then use the same board for prototyping and
product development.
Networking solutions providers such as Softing, Beckhoff, Automata, and IXXAT
offer a wide breadth of Industrial Ethernet support on Cyclone III and Cyclone IV E
FPGAs. Table 3 shows the Industrial Ethernet protocol standards supported by each
partner. While the INK is used to support Cyclone IV designs, Altera partners also
support a variety of Altera-based FPGA solutions, as illustrated in Figure 6.
Figure 6. Partner Industrial Ethernet Solutions
Softing offers the Real-Time Ethernet Module (RTEM), which targets PROFINET (IO),
EtherCAT, and Modbus/TCP on the same Cyclone III FPGA platform. This module
integrates “as is” directly into an existing product with minimal changes, and
communicates with the product’s main board via serial I/O, parallel I/O, or any
similar proprietary interface. For systems with an Altera FPGA designed into the
main PCB, Softing offers licenses for IP cores, protocol stack software, application
interfaces, and any additional design services required.
With their Industrial Ethernet Module (IEM), IXXAT supports Ethernet Powerlink,
EtherNet/IP, SERCOS III, EtherCAT, and Modbus TCP. The IEM is easily integrated
with products to deliver a quick and easy drop-in Industrial Ethernet solution. IXXAT
also provides hardware services and solutions to quickly integrate the IEM into an
existing product so it can quickly support the required Industrial Ethernet standards.
In addition, IXXAT licenses IP cores, protocol stack software, and application
interfaces for developers who want to develop their own FPGA boards.
The SERCOS I/II networking standard has been around for many years but only the
latest version, SERCOS III, is Ethernet based. SERCOS III upgrades the features of
SERCOS I/II with a deterministic real-time, high-performance communications
interface over Ethernet between motion controls, digital servo drives, and I/O
devices. If the design requires the SERCOS III protocol, Automata offers software
stacks, development boards, and design services.
The MotionFire (Motor Control) Development Kit from Arrow Electronics provides a
versatile global platform for evaluation and development of both motor-control and
Industrial Ethernet applications on the same board. The kit consists of a FireFighter
Cyclone III FPGA-based board and a FireDriver power board that drive two BLDC
motors (scalable up to 6 FireDriver boards). With open-source motor-control IP from
Unjo AB and Industrial Ethernet IP from Softing, MotionFire delivers the means to
evaluate motor-control applications across multiple Industrial Ethernet protocols.
Ethernet protocols and motor-control IP from other vendors can also be ported to this
platform.
If the design requires the EtherCAT Industrial Ethernet protocol, then the EtherCAT
specification, slave IP license, and software license can be obtained from the
EtherCAT Technology Group (ETG). Alternatively, systems integrators such as IXXAT
and Softing can implement the EtherCAT solution for the design. The ETG also
markets a Beckhoff evaluation kit that can be used to evaluate or prototype EtherCAT
implementations on the Altera Cyclone III FPGA.
The MercuryCode (DBC4CE55) development kit from EBV (Europe only) is another
comprehensive solution for implementing protocol-independent Industrial Ethernet
systems. The board has two RJ-45 Ethernet sockets, each driven by an Ethernet PHY
connected to the FPGA. With this board, all a designer needs to implement any
Industrial Ethernet standard is the upper-layer software, the Layer-2 hardware IP (or
MAC IP), and the Nios II processor. Reference designs for many Industrial Ethernet
protocols have been proven on the MercuryCode board (or its predecessor, the
DBC3C40 board) and are available today. The board also carries transceivers for CAN,
USB, UART, and LVDS interfaces for high-speed communication or for driving LCD
displays.
Summary
Ethernet technology for the industrial market brings many benefits and is expected to
show strong growth over the next five years. There are many Industrial Ethernet
protocol solutions available, each with their own particular set of advantages. What is
clear is that Ethernet technology will continue to advance, driving the evolution of
both new and current Industrial Ethernet solutions. Technologies like 1-Gbps and
10-Gbps Ethernet and real-time improvements to the current IEEE 802.3 standard will
deliver higher performance and better reliability. In addition, the focus on other
industrial areas such as security, redundancy, and safety protocols will undoubtedly
continue to drive change in Industrial Ethernet standards, providing a constant
challenge to industrial equipment manufacturers.
The advent of low-cost devices such as Cyclone IV FPGAs and embedded processor
IP such as Nios II processors has enabled cost-effective programmable solutions for
Industrial Ethernet. FPGAs deliver the ability to support any Ethernet-based
industrial communication protocol from the same base hardware as well as the
benefits of system integration, flexibility, and obsolescence protection that come with
programmable logic devices. The combination of reconfigurable hardware, SOPC
Builder, and the Nios II processor enables developers to easily modify both the upper
and lower layers of the Ethernet protocol without changing the physical hardware. As
existing protocols evolve and augment or supplant legacy fieldbus implementations,
and new protocols emerge, it is increasingly important to have a flexible, cost-effective
platform solution that can support any Industrial Ethernet protocol standard.
Implementing Industrial Ethernet in FPGAs has become necessary for all industrial
equipment manufacturers to help lower their total cost of ownership.
Further Information
■ Industrial Market:
www.altera.com/industrial
■ Nios II Processor: The World’s Most Versatile Embedded Processor
www.altera.com/nios
■ Cyclone III FPGAs: Unlimited Possibilities:
www.altera.com/cyclone3
■ Cyclone IV FPGAs: Lowest Cost, Lowest Power, Integrated Transceivers:
www.altera.com/cyclone4
■ Embedded Processing:
www.altera.com/embedded
Acknowledgements
■ Stefano J. Zammattio, Product Manager, Altera Corporation
■ Jason Chiang, Sr. Technical Marketing Manager, Altera Corporation
■ Stefan Weiher, Product Manager, IXXAT GmbH
■ Frank Iwanitz, Product Manager, Softing AG
■ Prof. Hans Doran, ZHAW InES